Decoupling Torsional Disturbance in a Vehicle Powertrain

ABSTRACT

A decoupler assembly for a motor vehicle driveline comprising a decoupler, an input driveably connected to a transmission output shaft and including a first connection that secures the input to the decoupler, and an output driveably connected to a final drive axle then to wheels of the vehicle, including a second connection that secures the output to the decoupler, and a support that provides bending continuity between the input and the output, the support permitting rotation of the input about an axis relative to the output, the decoupler, the first connection and the second connection providing resistance to such rotation.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to a motor vehicle powertrain, and, in particular, to an apparatus for torsionally decoupling components of a vehicle powertrain.

2. Description of the Prior Art

Power plants used in cars, SUVs, and trucks tend to generate torsional disturbances primarily of an impulsive nature, that degrade customer-perceived noise, vibration and harshness (NVH) quality both transients including clunk, thump, rattle, roughness, and steady state disturbances including gear whine, moan, growl. The durability of vehicle powertrains, whose sources for such disturbances are an engine and transmission, can be adversely affected by these disturbances.

Furthermore, a vehicle driveline, including its driveshaft and axle, has inherent torsional resonance modes that tend to be sympathetic to such disturbances or aligned with corresponding torsional modes within the transmission mechanism. This modal alignment causes significant amplification of both axle and transmission gear noise.

Several types of dampers are widely used in the industry to minimize the negative effects of such tensional excitation forces. Their performance is limited to a narrow tuning frequency range and amplitude reduction provided by the mass and damping. Moreover, their complexity, added weight and cost are undesired.

Other solutions use flexible couplings in lieu of typical U-joints or CV joints. However, these couplings tend to deteriorate significantly powertrain bending characteristics and significantly limit the driveline angle capacity required for a solid beam axle application, thus inducing risks to NVH quality and durability including critical speed.

SUMMARY OF THE INVENTION

A decoupler assembly for a motor vehicle driveline comprising a decoupler, an input driveably connected to a transmission output shaft and including a first connection that secures the input to the decoupler, and an output driveably connected to wheels of the vehicle, including a second connection that secures the output to the decoupler, and a support that provides bending continuity between the input and the output, the support permitting rotation of the input about an axis relative to the output, the decoupler, the first connection and the second connection providing resistance to such rotation.

The torsional decoupler reduces or eliminates the NVH issues efficiently from both transient events and steady state events. The device torsionally decouples the driveline from the power plant while maintaining the integrity of the powertrain bending characteristics and the angular capacity of the drive shaft.

The flexible decoupler provides an efficient, robust solution to torque induced disturbances with a low weight penalty, precise targeting of the torsional vibration characteristics to be eliminated, while leaving all other needed design characteristics unaffected.

The scope of applicability of the preferred embodiment will become apparent from the following detailed description, claims and drawings. It should be understood, that the description and specific examples, although indicating preferred embodiments of the invention, are given by way of illustration only. Various changes and modifications to the described embodiments and examples will become apparent to those skilled in the art.

DESCRIPTION OF THE DRAWINGS

The invention will be more readily understood by reference to the following description, taken with the accompanying drawings, in which:

FIG. 1 is a schematic side view of a motor vehicle powertrain that includes a torsional decoupler assembly;

FIG. 2 is cross sectional side view of a first embodiment of a decoupler assembly for use in the powertrain shown in FIG. 1;

FIG. 3 is a perspective view of the decoupler assembly shown in FIG. 2;

FIG. 4 is cross sectional side view of a second embodiment of a decoupler assembly for use in the powertrain shown in FIG. 1;

FIG. 5 is a perspective view of a fitting for the decoupler assembly shown in FIG. 4;

FIG. 6 is a perspective view of a second fitting for the decoupler assembly shown in FIG. 4; and

FIG. 7 is a perspective view of a second embodiment fitting for the decoupler assembly shown in FIG. 4.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The powertrain 10 of FIG. 1 includes an engine 12, transmission 14 driveably connected to the engine, transmission output shaft 16 and output flange 18, a decoupler 20, a first universal joint 22 having a flange 24, driveshaft 26, second universal joint 28 having a flange 30, and a inter-wheel differential 32, that transmits power differentially to axle shafts 34, which extend laterally to the wheels of the vehicle.

Output shaft 16 and output flange 18 are formed as an integral unit or are connected mutually such that they function structurally as a unit. Flange 24 is secured to universal joint 22 such that they function structurally as a unit.

Decoupler 20 provides bending continuity with unaffected overall rigidity, axial force continuity, and lateral force continuity between transmission output 16 and universal joint 22, but not torsional continuity. Axial force continuity provided by decoupler 20 between transmission output 16 and universal joint 22 is represented by vectors 36, 37. Lateral force continuity provided by decoupler 20 between transmission output 16 and universal joint 22 is represented by vectors 38, 39. Bending continuity provided by decoupler 20 between transmission output 16 and universal joint 22 is represented by vectors 40, 41, respectively. But torsional disturbance represented by vector 42 cannot be transmitted across decoupler 20 in either direction. But the nominal powertrain torque (DC torque) from output shaft 16 is entirely transmitted across decoupler 20 to the driveshaft joint 22.

A decoupler assembly 50 having the desired structural functions described with reference to FIG. 1 is illustrated in FIGS. 2 and 3. Transmission output shaft 16 is an input to the decoupler assembly 50. Flange 18 is formed with a series of tapped holes 52, spaced angularly about an axis 54 and aligned with holes 56 formed in a flange extension 58. A bolt 60 is fitted into each of holes 56, and the threads of bolts 60 engage the threads tapped in holes 52, thereby providing no bending, lateral force or axially force continuity between flange extension 58 and the transmission output shaft 16 and its flange 18.

A flexible disc decoupler 62 is not secured to output shaft 16. The flexible decoupler 62, which is preferably formed of flexible rubber or a flexible synthetic material, is formed with a series of holes 64, spaced angularly about axis 54 and aligned with holes 66 formed in flange extension 58. Cylindrical spacers 68, located in holes 62, each abut the axial face 70 of flange extension 58. An attachment bolt 72, fitted into each of holes 66 and each of sleeves 68, is engaged by a nut 74, thereby providing virtually no bending, lateral force or axially force continuity between flexible decoupler 62 and flange extension 58.

Decoupler 62 is also formed with a series of holes 76, spaced angularly about axis 54 and aligned with holes 78 formed in a positioning adapter 80. Cylindrical spacers 82, located in holes 76, each abut the axial face 84 of positioning adapter 80. An attachment bolt 86, fitted into each of holes 78 and each of sleeves 82, is engaged by a nut 88.

Flange extension 58 is supported on a cylindrical journal 90 of positioning adapter 80 by a bearing 92 such that flange extension is free to rotate about axis 54, but for the minimal torsional resistance provided by flexible decoupler 62, the connection provided by bolts 72 between flange extension 80 and decoupler 62, and the connection provided by bolts 86 between decoupler 62 and positioning adapter 80.

The universal joint 22 at the forward end of driveshaft 26 is secured to a fitting 94, which is formed with holes 96 that are aligned with tapped holes 98 formed in positioning adapter 80. Joint yoke with flange 94 is connected to positioning adapter 80 by bolts 100, which are fitted into holes 96 and engaged with the threads of tapped holes 98.

In operation, bending about any axis normal to axis 54 is transmitted between output shaft 16 and fitting 94 through the torsional decoupler 50 and is carried by adapter 58, bearing 92 and adapter 90. A flexible, low torsional stiffness load path between output shaft 16 and fitting 94 is provided by flexible decoupler 62, the connection provided by bolts 72 between flange extension 80 and decoupler 62, and the connection provided by bolts 86 between decoupler 62 and positioning adapter 80.

Decoupler 110, a second embodiment having the desired structural functions described with reference to FIG. 1, is illustrated in FIGS. 4-6. Fitting 112 includes a flange 114 formed with series of bolt holes 116, angularly spaced about axis 54 and by which output shaft 16 is secured to fitting 112. Fitting 112 includes three bosses 118 angularly spaced about axis 54 and formed with holes 120. A shoulder 122 provides a surface facing a decoupler disc 124, which is preferably formed of flexible rubber or a flexible synthetic material and with a series of holes 126, spaced angularly about axis 54 and aligned with holes 120. Bolts 128, fitted in holes 126, engage threads tapped in holes 120 and secure decoupler disc 124 and fitting 112 mutually. Fitting 112 includes a cylindrical journal 130 concentric with axis 54.

A second fitting 132 includes a flange 134 formed with series of bolt holes 136 angularly spaced about axis 54, by which fitting 94 or universal joint 22 are secured to fitting 132. Fitting 132 includes three bosses 138 angularly spaced about axis 54 and formed with holes 140. A shoulder 142 provides a surface facing decoupler disc 120, which is preferably formed with a series of holes 144, spaced angularly about axis 54 and aligned with holes 140. Bolts 146, fitted in holes 144, engage threads tapped in holes 140 and secure decoupler disc 124 and fitting 132 mutually.

Fitting 132 includes a cylindrical journal 148 concentric with axis 54 and surrounding journal 130. Roller bearings or needle bearings are located in an annular space between journals 130 and 148.

In operation, bending about any axis normal to axis 54 is transmitted between output shaft 16 and fitting 94 or universal joint 22 through the torsional decoupler 132. The load path for transmitting bending and lateral force is provided by the overlapping journals 130, 148. A highly flexible, low torsional stiffness load path between output shaft 16 and fitting 94 is provided by flexible decoupler 124, the connection provided by bolts 128 between fitting 112 and decoupler 124, and the connection provided by bolts 146 between decoupler 124 and fitting 132.

Each decoupler assembly 50, 110 may be installed at any interface in the vehicle driveline, but is preferably located at the transmission-to-driveshaft interface. Each decoupler 50, 110 maintains low vibration amplitudes caused by powertrain bending excitation moments by providing bending stiffness continuity. The decoupler assemblies 50, 110 bypass the torsional excitation disturbing moments through an independent elastic torsional spring having a low torsional stiffness. The decoupler assemblies 50, 110 decouple the driveline/driveshaft torsional modes of vibration from the engine/transmission torsional modes of vibration, preserve the universal joint that will the provide necessary angle capacity and shield the torsional decoupler from bending excessively, and dampen the torsional vibration amplitude for both transient events of steady state harmonics.

The decoupler assemblies 50, 110 may include flexible decouplers 62, 124 that are flexible rubber circular couplings as shown in the figure, or rubber pucks arranged in a circular fashion working in compression, or metallic springs arranged in circular fashion.

Preferably input shaft 16, flange 18, flange extension 58, positioning adapter 80, fitting 94, and fittings 114, 134 are formed of metal having a modulus of elasticity in the range 15.0×10⁶-30.0×10⁶ pounds per square inch.

The flexible decoupler 62 is sized to accommodate the driveshaft-to-transmission interface standard circular flange outer diameter for the given application. The inner diameter is sized to accommodate the adapter pilot with standard bearings. The rubber durometer can range from 50 to 65 with a thickness range of 15-30 mm. An acceptable range for its torsional stiffness is 100-4500 lb-in per degree, when assembled as shown in FIGS. 2 and 4 depending on the nominal transmitted powertrain torque and on the frequency range of the torque disturbances.

In accordance with the provisions of the patent statutes, the preferred embodiment has been described. However, it should be noted that the alternate embodiments can be practiced otherwise than as specifically illustrated and described. 

1. A decoupler assembly for a motor vehicle driveline comprising: a decoupler that provides a first bending stiffness about an axis; an input including a first connection that secures the input to the decoupler; and an output including: a second connection that secures the output to the decoupler, and a support that provides a second bending stiffness about the axis between the input and the output that is substantially greater that the first bending stiffness provided by the decoupler between the input and the output, the support permitting rotation of the input about the axis relative to the output, except for resistance to such rotation provided by the decoupler, the first connection and the second connection.
 2. The decoupler assembly of claim 1, wherein the support comprises: a first journal formed on the input and extending along the axis; a second journal formed on the output and extending along the axis; and first and second bearings located between and contacting the first journal and the second journal and spaced mutually along the axis.
 3. The decoupler assembly of claim 1, wherein: the input and output are formed of metal having a modulus of elasticity in the range 15.0×10⁶-30.0×10⁶ pounds per square inch; and the decoupler is formed of one of a flexible rubber having a durometer in a range 50-65 and a synthetic material having a shear modulus in the range 0.1×10⁶-0.3×10⁶ pounds per square inch.
 4. The decoupler assembly of claim 1, wherein: the decoupler is a disc formed with first axial holes spaced angularly about the axis, and second axial holes spaced angularly about the axis; the input includes a first fitting formed with the first journal and third holes aligned axially with the first holes; the output includes a second fitting formed with the second journal and fourth holes aligned axially with the second holes; first bolts connecting the first fitting and the decoupler mutually through the first holes and the third holes; and second bolts connecting the second fitting and the decoupler mutually through the second holes and the fourth holes.
 5. The decoupler assembly of claim 1, wherein: the first fitting further includes a first shoulder located adjacent a first surface of the decoupler; and the second fitting further includes a second shoulder located adjacent a second surface of the decoupler axially opposite the first surface.
 6. The decoupler assembly of claim 1, wherein: the input is driveably connected to a transmission output shaft; and the output is driveably connected to wheels of the vehicle through a final drive axle.
 7. A decoupler assembly for a motor vehicle driveline comprising: a decoupler; an input; a positioning adapter; a flange extension supported on the positioning adapter for rotation relative to the positioning adapter about an axis, secured to the input and to the positioning adapter for bending displacement as a unit, including a first connection that secures the flange extension to the decoupler; the adapter including a second connection that secures the adapter to the decoupler, and a support that provides bending continuity between the flange extension and the positioning adapter, the support permitting rotation of the input about an axis relative to the positioning adapter, the decoupler, the first connection and the second connection providing resistance to such rotation.
 8. The decoupler assembly of claim 7, wherein: the input and output are formed of metal having a modulus of elasticity in the range 15.0×10⁶-30.0×10⁶ pounds per square inch; and the decoupler is formed of one of a flexible rubber having a durometer in a range 50-65 and a synthetic material having a shear modulus in the range 0.1×10⁶-0.3×10⁶ pounds per square inch.
 9. The decoupler assembly of claim 7, wherein the support comprises: a first journal formed on the flange extension and extending along the axis; a second journal formed on the adapter and extending along the axis; and a bearing located in an annular space between and contacting the first journal and the second journal.
 10. The decoupler assembly of claim 7, wherein: the decoupler is a disc formed with first axial holes spaced angularly about the axis and spaced radially from the axis; the flange extension is formed with the first journal and second holes, each second hole being aligned axially with one of the first holes, and the first connection comprises first bolts connecting the flange extension and the decoupler mutually through the first holes and the second holes; the adapter is formed with the second journal and third holes, each third hole being aligned axially with one of the first holes, and the second connection comprises second bolts connecting the adapter and the decoupler mutually through the first holes and the third holes.
 11. The decoupler assembly of claim 7, wherein: the decoupler that provides a first bending stiffness about an axis; and the support that provides a second bending stiffness about the axis between the input and the output that is substantially greater that the first bending stiffness provided by the decoupler between the input and the output.
 12. A decoupler assembly for a motor vehicle driveline comprising: a decoupler formed with first axial holes spaced angularly about an axis, and second axial holes spaced angularly about the axis, the decoupler providing a first bending stiffness about the axis; a first fitting formed with third holes aligned axially with the first holes; a second fitting formed with fourth holes aligned axially with the second holes, the first fitting and second fitting providing a second bending stiffness about the axis between the first fitting and the second fitting that is substantially greater that the first bending stiffness provided by the decoupler; first bolts connecting the first fitting and the decoupler mutually through the first holes and the third holes; and second bolts connecting the second fitting and the decoupler mutually through the second holes and the fourth holes.
 13. The decoupler assembly of claim 12, wherein: the first fitting is formed with a first journal extending along the axis; the second fitting is formed with a second journal extending along the axis and spaced radially from the first journal; and first and second bearings located between and contacting the first journal and the second journal and spaced mutually along the axis.
 14. The decoupler assembly of claim 12, further comprising: an input including a first connection that secures the input to the decoupler; and an output including: a second connection that secures the output to the decoupler, and a support that provides a second bending stiffness between the input and the output that is substantially greater that the first bending stiffness provided by the decoupler between the input and the output, the support permitting rotation of the input about an axis relative to the output, except for resistance to such rotation provided by the decoupler, the first connection and the second connection. 